Abrasive Insole and Method of Manufacture

ABSTRACT

An abrasive insole and method of manufacture. The insole is integrated into the shoe at the time of manufacture. The insole provides a roughly textured surface to abrade the skin on the soles of the feet for purposes of cosmetic appeal and skin health. The abrasive insole works similarly to the textured, sandpaper-like tools that are used in pedicure to soften the skin of the foot by exfoliation. The method of manufacture involves a mold of a sand-and-polymer mixture to produce a flexible insole; one iteration is of 3/32 to 0.25-inch thickness.

TECHNICAL FIELD

The present disclosure relates to characteristic features of footwear; parts of footwear; and specifically to insoles that have an abrasive surface; low shoes; slippers characterized by the sole; and to methods of manufacturing the same.

BACKGROUND

Shoe insoles and replaceable insoles are made in various shapes and materials to support human posture and foot comfort. They may be molded into a shoe at the time of manufacture or constructed and sold separately. Some insoles have tactile surfaces that serve to massage the foot.

Abrasion tools are used in pedicure to slough dead skin and soften the soles of the feet. Tools for this purpose range from steel blades to pumice stones. Consumers use these tools for cosmetic and health purposes such as to keep foot skin from drying and cracking, which could lead to skin breaks that could introduce infection.

Polymers used in shoe manufacturing may be of the type of thermosetting polymers, resins or plastics, i.e., those which are hardened by curing from a soft-solid or viscous liquid prepolymer or resin. In the curing process, heat, pressure and sometimes an introduced catalyst are used to produce the resulting, hardened state of the material. Once hardened, a thermoset cannot be melted for reshaping. Thermoplastic polymers, on the other hand, can be reshaped into final form by melting, pressing or injection-molding.

Silicones (polysiloxanes a polymers that harden to a rubber-like material.

Overmolding is a process where a single part is created using two or more materials in combination. Typically the first material (the substrate) is partially or fully covered by subsequent materials (overmold materials) during the manufacturing process. The substrate material or part is placed into an injection molding tool at which point the overmold material is shot into, onto, or around the substrate. When the overmold material cures or solidifies, the two materials become joined together as a single part.

SUMMARY

An abrasive insole of a sand-and-polymer construction, molded into a shoe. The insole is of a rough texture that abrades the skin on the soles of the feet for cosmetic and skin-health purposes. The abrasive insole works similarly to the textured, sandpaper-like tools that are used in pedicure to soften the skin of the foot by exfoliation.

One iteration of the embodiment is manufactured by molding a sand and polymer mixture to produce a flexible insole. In some embodiments the insole is between 3/32″ to ¼″ thick. The flexible insole is co-molded into the shoe at the time of manufacture.

Another iteration is an after-market replacement insole that may be manufactured in specific sizes or cut to fit a range of shoe sizes and used to replace an existing insole. This iteration may be manufactured by rolling the aforementioned sand and polymer insole material into sheets and die-cutting it to fit various-sized shoes.

One skilled in the art understands that sand and silicone are two of many materials that can be combined to make an abrasive material, and that these materials may be manufactured in various hues, various grit sizes and varying densities.

An embodiment of the present invention is a method of manufacture in which sand and silicone are mixed and poured into a mold that produces an insole. The thickness of an insole may vary between 0.09375 and 0.5 inches. Various molds can be formed to produce insoles of varying footbed textures.

The insole may be manufactured with or without arch and side supports for fitting the shape of various types of feet.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective, front view of an iteration of the embodiment, shown installed in a sandal.

FIG. 2 is a perspective, rear view of an iteration of the embodiment, shown installed in a sandal.

FIG. 3 is a section view of an example embodiment.

FIG. 4 is a front, perspective view of another iteration of the embodiment shown separately and as inserted into a sandal.

DESCRIPTION

In FIG. 1 an example embodiment 100 shows a provided sandal 110, onto which is installed the insole 114 onto a outsole 112 to fit within the boundaries of an upper 116. One skilled in the art understands that the provided sandal represents any type of shoe.

FIG. 2, 100 shows in rear view an iteration of the embodiment 100, with the insole 114 installed in a provided sandal 110. Other reference numbers are shown for reference.

FIG. 3 is a section view of the embodiment 100 showing the insole 114 co-molded with the outsole 112 and fitting within the upper 116 of a sandal 110.

In FIG. 4 an iteration of the example embodiment 200 shows a provided sandal 210, onto which is installed the insole 214 to fit within the boundaries of an outsole 212 and an upper 216. One skilled in the art understands that the provided sandal represents any type of shoe.

These embodiments should not be construed as limiting. 

1. An apparatus and method of manufacture of an abrasive insole comprising: a polymer combined with sand; and said polymer-and-sand combination molded to form an insole of a shoe; wherein the polymer-and-sand combination comes in contact with at least the bottom of a foot when the shoe is worn.
 2. The apparatus and method of claim 1 wherein the polymer is a thermoplastic polymer.
 3. The apparatus and method of claim 1 wherein the polymer is a thermoset polymer.
 4. The apparatus and method of claim 1 wherein the polymer is silicone.
 5. The apparatus and method of claim 1 wherein the sand is basalt.
 6. The apparatus and method of claim 1 wherein the sand is garnet.
 7. The apparatus and method of claim 1 wherein the polymer-and-sand combination is co-molded with a sole of a shoe to form an insole of a shoe at a thickness of 0.09375″-0.25″.
 8. The apparatus and method of claim 1 wherein the polymer-and-sand combination is co-molded with a sole of a shoe forming an insole of a solid-core material.
 9. An apparatus and method of manufacture of an abrasive shoe insole comprising: a polymer combined with sand; and said polymer-and-sand combination molded in sheet form; and said sheet die-cut into shapes; wherein said shapes are configured to fit into a shoe.
 10. The apparatus and method of claim 9 wherein said shapes are specific to a given shoe size.
 11. The apparatus and method of claim 9 wherein said shapes are configured to be cut to fit a given shoe size.
 12. The apparatus and method of claim 9 wherein the polymer is a thermoplastic polymer.
 13. The apparatus and method of claim 9 wherein the polymer is a thermoset polymer.
 14. The apparatus and method of claim 9 wherein the polymer is silicone.
 15. The apparatus and method of claim 9 wherein the sand is basalt.
 16. The apparatus and method of claim 9 wherein the sand is garnet. 